Pro Track Athletes Get a Grip With 3-D Printed Equipment

Photo: Courtesy of Brian Babineau/New Balance

At first glance, the 4:01.44 indoor mile that Jack Bolas ran in New York doesn’t seem like that big a deal. But the real story wasn’t his fourth-place finish; instead, it was the fact the four-time All-American was the first professional athlete to run a race in 3-D printed equipment.

Specifically, the spike plates on the shoes Bolas wore in January were created by New Balance after a long research-and-development process focused on ensuring the shoes met his individual needs.

“I always wondered what it would be like to have custom shoes,” says Bolas. “They gave me a much more natural feel, with a perfect balance between the flex of the sole and still the responsiveness of a stiffer plate.”

The process started by putting Bolas into shoes wired with sensors to help New Balance designers understand how his foot interacts with the shoe. He also ran on tracks equipped with force plates that measured his impact with each stride. High-speed cameras added a detailed look at the interaction between his shoes and the track.

Photo: Courtesy of Scott Zeuhlke/New Balance

Katherine Petrecca, manager of studio innovations at New Balance, says the data allows the shoe to be configured to match an athlete’s specific movements. “We can customize the orientation and size of the plastic cleats and the number and location of the metal spikes based on the data,” she says.

The spike plates are printed using an SLS machine, then mated to a standard upper. Bolas tested several variations before choosing the model he wore in the race.

The possibilities for easy customization are nearly endless. Previously, a custom spike plate required an expensive injection molding process, but with the 3-D printers, the speed of production is much faster and the cost is slashed. Because it’s so much easier, runners can choose different designs based on their strategy for a particular race. “If you’re going to rely on a strong finishing kick, that means having lots of traction for running up on your toes at the end,” says Petrecca.

New Balance isn’t offering the technology to consumers yet, but it’s possible that the company might one day be able to print custom midsoles that are tailored to a runner’s weight, running style and cushioning preference. The company has even tested a model that is completely 3-D printed, with no traditional cloth upper.

For New Balance CEO Robert DeMartini, it’s these consumer applications that are most intriguing. “3-D printing unlocks an entirely new level of design, allowing us to elevate design within the company to ensure we bring consumers the best in both performance and design,” he says.